1. Innovating the Way You Automate!
Balluff
Innovating the Way You Automate!

2. Traditional Controls Cabinet
Parallel wiring is:
labor intensive,
prone to human errors and,
high maintenance.
no diagnostics
Traditional Controls Cabinet also means centralized approach to I/O architecture.
Bringing all connections for sensors back to centralized cabinet- requires tremendous amount of labor efforts and controls engineering debugging time.
Long cable runs, cutting stripping, crimping, labeling and terminating individual wires.
Same problems repeat during install and commissioning!
16. September 2018
Balluff Inc.

3. Evolution of I/O Architecture Philosophies
Network Distribution I/O
16. September 2018
Balluff Inc.

4. Safety I/O still remained in the cabinet
Requires considerable amount of wiring, routing and design efforts
There are different approaches to safety available these days!
In typical workcells, safety is used at many different places and requires considerable amount wiring
16. September 2018
Balluff Inc.

5. Traditional Approach to Safety I/O
Fieldbus with IO-Link interface
Safe processing
IO-Link devices
Standard sensors/actuators
Standard safety sensors/actuators
Standard I/O and Safe I/O were two different worlds!
16. September 2018
Balluff Inc.

6. Recent Approach to Safety I/O
Safe processing
Fieldbus with IO-Link interface
Expanded PLC with Safety controller, but Safe I/O remained separate inside the cabinet.
IO-Link devices
Standard sensors/actuators
Standard safety sensors/actuators
16. September 2018
Balluff Inc.

7. Recent Approach to Safety I/O
Fieldbus with IO-Link interface
IO-Link devices
Standard sensors/actuators
Standard safety sensors/actuators
Safety I/O started migration closer to the standard I/O with IO-Link hubs (controlling power through safety relays)
16. September 2018
Balluff Inc.

8. New Approach to Safety I/O
Control level Safety PLC
Fieldbus with IO-Link interface
Utilizes the same IO-Link master
Use same M12 standard prox cable to add IO-Link Safety hub
Control not only Safety I/O but also standard I/O as need be
IO-Link devices
Standard sensors/actuators
16. September 2018
Balluff Inc.

9. New Approach to Safety I/O- Step 1
Availability of the approach on PROFINET
Utilizing black-channel tunneling principle with PROFI-SAFE
Control level Safety PLC
Fieldbus with IO-Link interface
Power over 7/8"
Tunneling Black-Channel principle
IO-Link devices
System Requirements
F-CPU (Failsafe CPU) controller and software for fail-safe programming
PROFINET with PROFISafe
Safety functions (E-stop, light curtain etc.) programmed through safety assemblies
Uses AIDA specifications for connection to safety devices
Standard sensors/actuators
AIDA: Automatisierungs-Initiative Deutscher Automobilisten
16. September 2018
Balluff Inc.

10. Benefits of this approach
Faster machine build
M12 connector for making fast connections
Avoid wiring mistakes
No electrical specialists necessary
Low efforts required for change
Use of existing topology
IO- Link with single master
Scalable from 1 to X devices, automation and safety mixed
New possibilities
Simple replication of (PLC) projects for machine building
Pre-wiring of machine segments
Reduces parallel wiring and control cabinet volume (relays)
Reduced part replacement downtime.
Sensor/field: M12 connection
Safety Hub and Master: Mechanisms from the controller
16. September 2018
Balluff Inc.

11. A Word on PROFIsafe PROFIsafe:
Uses standard PROFINET or PROFIBUS for communication.
Media independent approach
Also an international standard IEC
Can be used for safety applications up to:
SIL3 IEC 61508/ IEC62061
Category 4 EN 954-1
PLe ISO
Source: US PNO organization
16. September 2018
Balluff Inc.

12. PROFIsafe Black-Channel Principle
Functional safety controller
Functional safety device
PROFIsafe communication has no impact on standard communication
PROFIsafe secures the whole path from origination of the signal to where it is processed.
Source: US PNO organization
16. September 2018
Balluff Inc.

13. ProfiSafe - telegram structure per IEC 61784-3-2
Source: US PNO organization
16. September 2018
Balluff Inc.

14. Existing Topology – Added Value
Safety sensors/actuators
Standard sensors/ actuators
Fieldbus with IO-Link interface
IO-Link devices
Safety PLC
16. September 2018
Balluff Inc.

15. PROFINET connection to Safe PLC (PROFISAFE)
7/8" Power cable up to 9A
PROFINET connection to Safe PLC (PROFISAFE)
3-wire M12 standard cable up to 20m
Power 7/8" connector
PROFINET IO-Link Master
4 Port,
8 Port
16 Port
PROFIsafe IO-Link I/O hub
8 ports M12
4x Safe Input
2x Safe Output
2x Safe I/O and Standard I/O
16. September 2018
Balluff Inc.

16. PROFISafe IO-Link I/O hub
Certified to EN/IEC 61508:2011 and EN/IEC 62061: A1:2013 up to SIL 3.
For 1-channel use of the inputs SIL 2 can be achieved.
Per EN ISO :2008 the device is certified up to PL e and according to Category 4.
For 1-channel use of the inputs PL d can be achieved.
1-channel operation is included in the certification.
Max. cycle-time for PROFIsafe communication 20ms (worst case scenario)
Robust compact design with built-in dual redundant circuit.
16. September 2018
Balluff Inc.

17. PROFISafe IO-Link I/O hub
4x Safe Inputs 5-pin
2x Safe Outputs 5-pin
16. September 2018
Balluff Inc.

18. Safety Connection Map
4 x
2 x
2 x
16. September 2018
Balluff Inc.

19. Multifunction Display
status and error LEDs
LED display with background illumination
sub-menu/entry key
Menu selection key
Display used for setting up Safety node address (F-address) and to read other parameter and log data
Parameters:
Error logs (up to last 7 error entries)
Port settings and status
System information (SIL Level, Product ID, etc..)
16. September 2018
Balluff Inc.

20. Balluff Safety Portfolio
BNI
BAM-ES
BID…00
BID...M/E
BLG
BNS
16. September 2018
Balluff Inc.

21. Balluff Light Grids (BLG)
Safety Light Curtains (EN )
Dimensions:
32 x 150…1800 x 37 mm
Detection capability/resolution:
Finger (14 mm)
Hand (30 mm)
Body (2-4 beams)
Housing material:
Aluminum
Design:
Black/yellow housing
Connection:
M12 connector, 5-pin
Body protection
Hand protection
Finger protection
16. September 2018
Balluff Inc.

22. Balluff E-Stop (BAM-ES)
Dimension:
80 x 106 x 72 mm
Housing material:
Plastic
Design:
Black/yellow housing,m red mushroom pushbutton, white
EN E-stop
EN ISO 13850
Connection:
M12 connector, 5-pin
Fixed
safe (positive) normally closed
16. September 2018
Balluff Inc.

23. Balluff Door Interlock Switches (BID)
Dimension:
40 x 150 x 44 mm (+50 mm per additional element)
Housing material:
Cast aluminum
Design:
Yellow base housing, black actuation head
Low coding level
EN ISO – Interlock devices
EN Safety Switches
Connection:
M12 connector, 5-/8-pin (without/with retaining function)
Interlock
Issue stop command
Body protection
16. September 2018
Balluff Inc.

24. Safety @ Balluff -- Thank YOU!!
Safety Sensor/Actuators
Standardsensors/ actuators
Fieldbus with IO-Link interface
IO-Link devices
Safety PLC
16. September 2018
Balluff Inc.